Plastic composition and method of making same.



' terial for forming the record surface. of, du-

UNITED STATES. :PATENT OFFICE.

JONASWU; AYISWORTH, EAJS'I. ORANGE, NEW JERSEY, ASSIGrlVOR, BY DIREGT AND MESNE'ASSIG'NMEN-TS, TO OONDENSITE COMPANY OF. AMERICA, OF EAST ORANGE, NEW JERSEY, A CORPORATION OE NEWJERSEY,

rLAsmcpoMrosrrmN AND METHOD or MAKING SAME 1,102,631; No Drawing.

and State of. New Jersey, have invented certain new and. useful Im rovements', in Plastic' Compositions and Me beds of Make ing Same, of whichthe following is a de- 1 scription 1 My invention relates to--a newcoinp'o si tion of matter and process of makingthe same; itowill bespecifically described in its application to the manufacture. ofnduplicate sound. records 1 of either, the cylindr cal or disk type. 5 1 f a llhe ob'ect of the invention is thejormation of a. roduct which has certtiilfqualities and re nements which ithas heretofore been impossible to attain,

Condensation products of phenolic bodies and formaldehyde or other substance containing themethylene radical OH,',.in their final hard infusible condition, suchas' are.

obtained by methods disclosed in my applications Serial Nos. 496,060, filed Mayli,

1909, and 543,236 filed. February 11,1910,

and Patentv No. 1,020,593,, grantedv March 19,1912, are preeminently suitedas themarecords, and the present-in plicate I sound be practised. for making the vention may same of improved quality. It. is customary in the manufacture of sound records. of: va-

rrous COIIIPOSIt-IOIIS aDd 1n the production of compositions tobe molded generally, to. incorporate 3112111611. filling body w1th..the:com-.

' position for. the-purposeof cheapening, and

toughening the same. Such a procedure, however, resultsin the formation of, a sound record or other object of non-uniform. tex: ture, 'fromwhich circumstance arise certain V difficulties.

' The improvedqualities of the composition comprising my. presentinventioir, articu-v larly whenthe salne is formedzinto a: sound record are attained by. forming-the record or. other object of a, uniform texture andat the same time-obtaining-the advantagesin manufacture and-strength offs-record. or other objectof homuniformtexture. That is to say, my improved composition. in its final-condition1:is--a homogeneous mass of a fin l. infusibleinsoluble phenolicv condense tion product. At thesame time the advan- Specification of Letters Patent.

Patented July 7, 191 4.

Application filed'Aug'ust 6, 1910. Serial N o. 575,970.

tages of employing anon-homogeneous mass formed by the incorporation of a powdered :or fibrous filling-niaterialwith a binder are .attained by the process I employ, in which a final hard infusible insoluble phenolic condensation product in comminuted condition is used as the filling body, being thoroughly mixed through a fus'iblesoluble phenolic condensation product, with which is mixed a hardening agent such as hexamethylene-tetra-amin, formaldehyde, or a polymer thereof, the hardening agent and the fusible product reacting upon application of'sufiicient heat to form the final infusible product, the 'comminuted infusible final product used as a filler becoming, an

tion of the'reaction. p

In my. application Serial- No. 543,236,

ofusinginfusible condensation products in powdered form as a filling agent in a use of fillin bodies in compositions of the character referred to is advantageous in that ithey strengthen the product and overcome or counteract the stresses which are set up :in the product, and cheapen and facilitate {manufacture Products of nonuniform abovereferred to, I allude to the possibility.

com-. position for making sound records. The

integral part of the mass upon the compleitexture, however, that is, those containing leased,.w.h ich causes the surface of the objectto be made microscopically rough. Such records are also more susceptible to atmoscontaining no such filling bodies, and if the stylus is apt to be worn thereby.

My invention comprises three I steps. First, the production of a comminuted powtheporesof the fillerto be compressed and" subsequently expand. when pressure'is repheric influence generally than are records filler is of a mineral nature, the reproducing der of an infusible condensation product'of full degree of hardness; "Second, the incorporation of the comminuted powder with an unhardened or fusible condensation product capable of b'eingmtransformed intotheinfusible variety b eating to the required temperature' T ird, the molding of the same in a sound record matrix or other'm'atri'x.

The first step may known ways and mechanically comminuting fusible product the same to the required state of sub-division. The "final infusible product may, however, be more easily crushed 'or com-' minuted in the following manner-f by causing the reaction to take placef in suchia.

manner in a volatile solvent that a porous,

easily comminuted product is' obtained. To accomplish this result the necessary ingredi cuts from which the final-product is formed by heat application are dlssolved in a suit-- been rendered microscopically porous by its formation in the solvent, may be comminuted while still contained in the'solvent or after removal of the latter. Amyl acetate, alcohol, amyl alcohol, or other common solvents ofthe ingredients 'used'for form- I ing'the product may be used i'nthis process.

f to form'the final product niay be. the 's'ub stances dissolved in the solvenifil ii ld'the final:

Phenol, or the like, together-withisufficient formaldehyde or other substance containing the methylene radical CH substance formed in .one step from these primary ingredients, or if des red, a fusible soluble phenolic condensationproduct, such asdescribed in my applications and atent above referred to, togethr'With; approximately 10% or other suitableproportionbf methylene-containing agent to react- I with the fusible product to form-"thefinal prod uct, may be the. ingredients used. If desired, a non-volatile solvent-or a plasticity agent, such as described n my applications a ove referred-.to, such, for example, as mono-chloro-naphthalene, may also be. a component of thei'reacti'ngimass, in which case the dried infusible'powder to be used as a filling body will possess the property of being plastic while ct to a eater degree than whenthe con'l'min uted densation product" without such plasticity agent is useda's a'filler.

Mi ha in 19 e ewaa a s v arriedout bforming the final product in any of t e well.

fusi hardening agent as a plastic mass may be toreact togethcr v fusible final roduct, asfisfdescribed 1n my "gpplications' erial No."543,-236 and; Pat ent i b t ip ish deredmas's .or the plastic'jina'ss'in a suitable final con-.

resin of thecharacter described in my applications above referred to, together with a hardening agent, may be dissolved-in a suitable solvent and thoroughly mixed with the comminuted infusible roduct and dried,

and the powder thus obtained pressed in the Or a mixture of the fusible and molds. v infusible condensation products, together with a hardening agent, all in comminuted out previous use 0 solvent. Or thirdly, the

le condensation product mixed with the mixed with the infusible condensation product in powdered condition and mixed thoroughly on heated r0lls,-s1ich'as are used in compounding rubber and allied plastic com-' positions. This latter method is preferred when'the mass is desired to have good flowing qualities when compressed in the molds. The proportions in the first two cases when the fuslble andflinflgsible powders are mixed, or the powder and the solutionof the fusible mass are mixed are-100 parts infusible comminuted condensation product and 15 to 100 parts fusible condensation product mixed with a hardening agent.

condition, may be pressed in the molds with- The/proportions in the third case clted may be'-'-100 parts of the fusible. roduct" mixed with a hardening agent, and 0" to parts of the infusible comminutedcondensation product. The" hardening agent referred tois preferably hexa methylene-tetra-amin in roper proportion-to'combine the fusilefcondensati'oni .prdductgto fform the ino.' 1,020,593 above referredto;

- fThe .third'ste ofjmdldingfthe mass may matrixand heati'h cause, the-same to become" sufficiently p astitf tfefpIro'perly 'fillthe ;mold, and further heating/to harden the whale t6 "its fullgdegree-g-"ef hardness and renderv the same infusible throughout. The

- article may be removed" "from the mold after. cooling, which 'causesaslight contrac-v tion. -Or'th e massmay-be com ressed in the heated 'mold to roperly conso "dateand form thefarticl'e', t operation, however,

not. being continued,- pr a 'suflicientlength of time to convert the fusible component of the mass 5 into its 'infusible' state, and subsequently heating the moldedfobjectj'after its removal from" the matrix to harden it into N y v N itsfifnallinfusible condition.- T e' se n epa Pm mam? .WhiIe-" 'the'. invention ;is specifically dewith the manufacture of sound records, it is obvious that it may be used for molding Various products.

Having now described my invention, what I claim and desire to protect by Letters Patent is as follows 1. The process of forming hard phenolic condensation products, whlch consists in mixing thoroughly together a filling body consisting of a hard, infusible final phenolmethylene condensation product in comminuted condition with a binder comprising a fusible phenol-methylene condensation product and a methylene-containing hardening agent for said fusible product, and heating the mass under conditions suitable to cause the final hardening reaction between said fusible product and hardening agent and the formation of a' homo eneous mass in which said filling body is integrally bound, substantially as described.

2. The process of forming hard condensation products, which consists in mixing thoroughly together-a filling body consisting of a hard, infusible final phenolmethylene condensation product in comminuted condition with a binder comprising fusible phenolic and methylene-containing ingredients adapted to form, u on sufiicient heating, a final infusible con ensation product of the same character as the said filling body, and heating the mass under conditions suitable to cause the final hardening reaction between the ingredients of the binder and the formation of a homogeneous uniform hard infusi'ble product including said filling body, substantially as described.

3. The rocess of forming hard phenolic condensatlon products, consisting in incorphenolic this 1st day of Augu porating ahard infusible phenolic condensation product in comminuted condition with a fusible phenolic condensation product and hexa-methylene-tetra-amin and a plasticity agent, heating the mixture and causing the final hardening reaction between the active components of the mass to take lace, substantially as described;

4. The process of forming hard phenolic condensation products, consisting in' comminuting to powder a hard infusible insoluble phenolic condensation product having a plasticity agentincludedv therein,

thoroughly mixing the same with a fusible phenohc condensation product and a small percentage of a methylene-containing substance, heating the mixture and causing the final hardening reaction between the fusible product and the said substance to take place, substantially as described.

5. The process of forming sound records, which consists in mixing together a fusible phenolic condensation product, a small percentage of a methylene-contaimng substance,

and a hard infusible final phenolic conden- 

